Once I gutted the doors on my '68 coupe I discovered pretty significant rust holes where the window exterior chrome molding strip was mounted. Not sure how to proceed, door skin removal for access? Did you /others come across this issue? Thx for any guidance.

Thankfully that's one issue I didn't have to deal with directly, I just had minor surface rust.

Without seeing any photos it's a bit tough to suggest exactly how to proceed. However, based on your description it sounds like your issue is occuring in the area shown being wiped off in this photo.

If you have "pretty significant rust holes" it sounds like a repair will definitely be required. It seems to me the right way to fix the area will be to pull off the door skin, cut out the corroded area and then weld in a patch panel. Pulling the door skin will be a pain but will likely make the repair work easier.

Depending on how many rust holes you have, and how big they are, I wonder if it would be possible to use something like a Dremel tool to cut out the corroded area and then weld in a patch panel using a series of spot welds to avoid overheating the fiberglass behind it. Once welded in place you'd then have to grind the welds smooth. This approach may save you some effort provided the deterioration isn't too extensive.

What do you think?

Someday I'll finally be able to drive my Vette, but for now I'll just admire all the pieces...

Hi Tim,
You got it. That's the area. Looks like we concur. Holes vary from 3/8" to 3/4" and some corrosion reaches up to the top edge. Both your suggestions are what we've considered. Another is to cut the interior steel panel away, then do the patch, then reweld the interior cut away piece back into position, ugh. I don't weld. I am also going to look for donor doors (but good luck on '68 only style). Or drive them over to a pro.......$$$$$$$

If there's a local metal fabrication shop you might be able to take your doors there and pay them by the hour to do the work. Either way you'll need someone who knows what their doing, it'll be fairly delicate work.

These corrosion repairs are a real pain...

Someday I'll finally be able to drive my Vette, but for now I'll just admire all the pieces...

Cut out the damaged area and then trim a replacement piece to fit. Once you have that take a longer piece of metal to straddle the patch piece and extend onto the sound metal on either side. You'll need several inches of extension on either side. Then, using a really good epoxy adhesive, glue the components together.

It might do the trick. I wouldn't take this approach if the area in question is intended to be structural though. It's tough to tell just looking at the photo but it seems the intent of the metal framing here is to provide some rigidity to the door skin.

Someday I'll finally be able to drive my Vette, but for now I'll just admire all the pieces...

Be aware of the fact that the '68's doors are not just unique because of the button style door openers, but also that the outer weather strip mounts to the holes you show but also the inner window felt on the '68 mounts to the slots in the door while all the other C3 years the same felt mounts to the door panel, not to the door itself. The weather strip pieces which snap into these holes will not fit unless the holes are in the exact location and the correct size, and the same with the inner felt strips.

If you make your own replacement pieces, you must be exact.

Last edited by rbryce1 on Apr 7th, 2016 2:25 pm, edited 1 time in total.

Thanks to both of you for the replies. I will take what I now know and consult with my nephew a few states away. He is in the fine automobile restoration business (Ferrari, Bugatti, etc). I suspect we'll either do something along the lines that you two have laid out, or locate some donor doors.